Assembly drum and system and method using the same for the automated production of e-vapor devices

ABSTRACT

An assembler system for manufacturing vapor-generating articles may include a rotatable assembly drum including an outer face and a flute in the outer face. The flute is structured and arranged to hold a first section and a second section of the vapor-generating article. The system also includes a first mechanism that translates the first section relative to the second section while the first section and the second section are in the flute. The system additionally includes a second mechanism that rotates the first section relative to the second section while the first section and the second section are in the flute. The translating and the rotating connect the first section to the second section to form the vapor-generating article.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.14/883,980, filed Oct. 15, 2015, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional No. 62/064,892, filed Oct. 16, 2014, theentire contents of each of which are incorporated herein by reference.

BACKGROUND Field

This disclosure relates generally to systems and methods formanufacturing vapor-generating articles and, more particularly, tosystems and methods for manufacturing electronic vaping articles.

Description of the Related Art

Conventionally, electronic vapor-generating articles are manufacturedvia a number of manual operations. However, such operations are not onlylabor intensive and time consuming but also more prone to inconsistency.

SUMMARY

Some example embodiments described herein are directed to automatedprocesses for use in the manufacture of electronic vapor-generatingarticles, such as electronic vapor devices, regardless of their size andshape. Aspects are directed to an automated assembler workstation foruse in manufacturing electronic vapor devices. The assembler workstationmay include a rotatable assembly drum having a cylindrical drum surfacewith flutes that are configured to hold first and second sections of anelectronic vapor device. The assembler workstation may include amechanism for causing translational movement of the first sectionrelative to the second section within the flute, and a mechanism forcausing rotational movement of the first section or the second sectionor both within the flute. The assembler workstation may be structuredand arranged such that the translational movement and rotationalmovement result in connecting the first section to the second section toform a fully assembled component, such as an electronic vapor device. Inthis manner, the assembler workstation is useful as an automated systemfor manufacturing electronic vapor devices.

In accordance with an example embodiment disclosed herein, there is anassembler system for use in manufacturing vapor-generating articles. Thesystem includes a rotatable assembly drum including an outer face and aflute in the outer face. The flute is structured and arranged to hold afirst section and a second section of the vapor-generating article. Thesystem also includes a first mechanism that translates the first sectionrelative to the second section while the first section and the secondsection are in the flute. The system additionally includes a secondmechanism that rotates the first section relative to the second sectionwhile the first section and the second section are in the flute. Thetranslating and the rotating connect the first section to the secondsection to form the vapor-generating article.

According to another example embodiment, there is a method of assemblinga vapor-generating article. The method includes receiving a firstsection of the vapor-generating article and a first section of thevapor-generating article in a flute of a rotatable assembly drum whilethe assembly drum is rotating. The method also includes moving the firstsection toward the second section while the first section and the secondsection are in the flute and while the assembly drum is rotating. Themethod additionally includes connecting the first section to the secondsection while the first section and the second section are in the fluteand while the assembly drum is rotating, wherein the connecting thefirst section to the second section forms the vapor-generating article.The method further includes transferring the vapor-generating articleout of the flute while the assembly drum is rotating.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects are further described in the detailed description whichfollows, in reference to the noted plurality of drawings by way ofnon-limiting examples of embodiments, in which like reference numeralsrepresent similar parts throughout the several views of the drawings.

FIGS. 1 a, 1 b, 1 c, and 1 d show electronic vapor devices in accordancewith various example embodiments;

FIG. 2a is a block diagram of a process for automated assembly ofelectronic vapor devices in accordance with an example embodiment;

FIGS. 2b-2d show aspects of systems and methods for the automatedmanufacture of electronic vapor devices using rotating drums inaccordance with an example embodiment;

FIG. 3 shows aspects of a system for the automated assembly ofelectronic vapor devices in accordance with an example embodiment;

FIG. 4 shows a flute of an assembly drum in accordance with an exampleembodiment;

FIGS. 5a-5c show aspects of connecting a cartridge unit and a batterysection in a flute of an assembly drum in accordance with an exampleembodiment;

FIGS. 6 and 7 show aspects of an assembly drum and belts in accordancewith an example embodiment;

FIGS. 8a and 8b show aspects of an assembly drum, flute, and belt inaccordance with an example embodiment;

FIG. 9 shows a cutaway view of a portion of an assembly drum and amanifold in accordance with an example embodiment;

FIG. 10 shows aspects of a manifold in accordance with an exampleembodiment; and

FIG. 11 shows a flow diagram that illustrates steps of a process inaccordance with an example embodiment.

DETAILED DESCRIPTION

Various aspects will now be described with reference to specific formsselected for purposes of illustration. It will be appreciated that thespirit and scope of the apparatus, system and methods disclosed hereinare not limited to the selected forms. Moreover, it is to be noted thatthe figures provided herein are not drawn to any particular proportionor scale, and that many variations can be made to the illustrated forms.Reference is now made to FIGS. 1-11, wherein like numerals are used todesignate like elements throughout.

Each of the following terms written in singular grammatical form: “a,”“an,” and “the,” as used herein, may also refer to, and encompass, aplurality of the stated entity or object, unless otherwise specificallydefined or stated herein, or, unless the context clearly dictatesotherwise. For example, the phrases “a device,” “an assembly,” “amechanism,” “a component,” and “an element,” as used herein, may alsorefer to, and encompass, a plurality of devices, a plurality ofassemblies, a plurality of mechanisms, a plurality of components, and aplurality of elements, respectively.

Each of the following terms: “includes,” “including,” “has,” “'having,”“comprises,” and “comprising,” and, their linguistic or grammaticalvariants, derivatives, and/or conjugates, as used herein, means“including, but not limited to.”

Throughout the illustrative description, the examples, and the appendedclaims, a numerical value of a parameter, feature, object, or dimension,may be stated or described in terms of a numerical range format. It isto be fully understood that the stated numerical range format isprovided for illustrating implementation of the forms disclosed herein,and is not to be understood or construed as inflexibly limiting thescope of the forms disclosed herein.

Moreover, for stating or describing a numerical range, the phrase “in arange of between about a first numerical value and about a secondnumerical value,” is considered equivalent to, and means the same as,the phrase “in a range of from about a first numerical value to about asecond numerical value,” and, thus, the two equivalently meaning phrasesmay be used interchangeably.

It is to be understood that the various forms disclosed herein are notlimited in their application to the details of the order or sequence,and number, of steps or procedures, and sub-steps or sub-procedures, ofoperation or implementation of forms of the method or to the details oftype, composition, construction, arrangement, order and number of thesystem, system sub-units, devices, assemblies, sub-assemblies,mechanisms, structures, components, elements, and configurations, and,peripheral equipment, utilities, accessories, and materials of forms ofthe system, set forth in the following illustrative description,accompanying drawings, and examples, unless otherwise specificallystated herein. The apparatus, systems and methods disclosed herein canbe practiced or implemented according to various other alternative formsand in various other alternative ways.

It is also to be understood that all technical and scientific words,terms, and/or phrases, used herein throughout the present disclosurehave either the identical or similar meaning as commonly understood byone of ordinary skill in the art, unless otherwise specifically definedor stated herein. Phraseology, terminology, and, notation, employedherein throughout the present disclosure are for the purpose ofdescription and should not be regarded as limiting.

Aspects described herein are directed to an assembler workstation foruse in manufacturing electronic vaping articles including, but notlimited to, electronic vapor devices. Embodiments are described withreference to electronic vapor devices, but it is understood that aspectsdescribed herein may be used with any type of electronic vaping articleand, more generally, any type of vapor-generating article. The assemblerworkstation described herein includes a rotating, cylindrical assemblydrum that holds a first section and a second section of an electronicvapor device, and mechanisms that move the first section and the secondsection into connected engagement with one another while the firstsection and the second section are held in a flute on the assembly drum.The first section may be a cartridge unit of an electronic vapor deviceand the second section may be a battery section of the electronic vapordevice, such that the assembler workstation is useful for assemblingelectronic vapor devices during manufacturing operations.

Electronic Vapor Device Layout

Referring to FIGS. 1a and 1 b, an electronic vapor device (article) 60is provided and comprises a replaceable cartridge (also called a firstsection or cartridge unit) 70 and a reusable fixture (also called asecond section or battery section) 72, which in a non-limitingembodiment are coupled together at a connection 205. In exampleembodiments, the first section 70 includes a first connection structure501 and the second section 72 includes a second connection structure 502that is configured to engage the first connection structure 501 forcoupling the first section 70 to the second section 72 to form acomplete electronic vapor device 60. The connection structures 501 and502 may be any suitable connection structures, such as male and femalethreaded connectors, a bayonet and snug-fit receiver, detent, clampand/or clasp.

Generally, the second section 72 may include a puff sensor that isresponsive to air drawn into the second section 72 via an air inlet port45 adjacent the free end or tip of the electronic vapor device 60, abattery, and control circuitry. The disposable first section 70 mayinclude a supply region (reservoir) and a heater that vaporizes apre-vapor formulation that is drawn from the supply region through awick. A pre-vapor formulation is a material or combination of materialsthat may be transformed into a vapor. For example, the pre-vaporformulation may be a liquid, solid, and/or gel formulation including,but not limited to, water, beads, solvents, active ingredients, ethanol,plant extracts, natural or artificial flavors, and/or vapor formers suchas glycerine and propylene glycol. In a non-limiting embodiment, thesupply region may be a liquid supply region that contains an e-liquid.

The first section 70 may be a vaporizer section and may include an outerhousing 6 that houses the liquid supply region, heater, and wick. Uponcompleting the connection 205, the battery of the second section 72 isconnectable with the electrical heater of the first section 70 uponactuation of the puff sensor. Air may be drawn primarily into the firstsection 70 through one or more air inlets 44 during drawing action uponthe mouth end of the first section 70. The drawing action iscommunicated to a puff sensor in the second section 72 which causes thebattery-powered heater to vaporize some of the liquid from the liquidsupply region. The vaporized liquid is entrained in the air that isdrawn in through the one or more air inlets 44 and delivered to themouth of the adult vaper via one or more ports at the mouth end of thefirst section 70. As shown in FIG. 1d , the one or more air inlets 44′may be located at a structure associated with the connection 205,including but not limited to a connector ring between the first section70 and the second section 72.

In a non-limiting embodiment, once the liquid of the cartridge is spent,only the first section 70 is replaced. An alternate arrangement shown inFIG. 1c includes an implementation in which the first section 70 and thesecond section 72 are integrally attached, such that the entireelectronic vapor device 60 is disposed once the liquid supply isdepleted. In such a case, the battery type and other features might beengineered for simplicity and cost-effectiveness, but generally embodiesthe same concepts as in a non-limiting embodiment in which the secondsection is reused and/or recharged.

The electronic vapor device 60 may be about 80 mm to about 110 mm long,such as about 80 mm to about 100 mm long and about 7 mm to about 10 mmor more in diameter. For example, in a non-limiting embodiment, theelectronic vapor device 60 is about 84 mm long and has a diameter ofabout 7.8 mm. Implementations are not limited to these dimensions, andaspects described herein may be adapted for use with any size electronicvaping article.

At least one adhesive-backed label may be applied to the outer housing 6of the first section 70. The label completely circumscribes theelectronic vapor device 60 and can be colored and/or textured. The labelcan include holes therein which are sized and positioned so as toprevent blocking of the air inlets 44.

The outer housing 6 may be formed of any suitable material orcombination of materials. Examples of suitable materials include metals,alloys, plastics, paper, fiberglass (including woven fiberglass) orcomposite materials containing one or more of those materials, orthermoplastics that are suitable for food or pharmaceuticalapplications, for example polypropylene, polyetheretherketone (PEEK),ceramic, and polyethylene. It can be beneficial for the material to belight and non-brittle. In a particular implementation, the outer housing6 may be composed of metal (e.g., aluminum or aluminum alloy).

Automated Manufacture Using Rotating Drums

FIGS. 2a-2d show aspects of systems and methods for the automatedmanufacture of vapor-generating articles (such as, by way of example,electronic vapor devices) using rotating drums in accordance herewith.FIG. 2a is a block diagram of a process for automated assembly ofelectronic vapor devices in accordance with an example embodiment. Theprocess may include assembling cartridge units (first sections) at step10; assembling battery sections (second sections) at step 11; andassembling a combined article including a respective cartridge unitconnected to a respective battery section at step 12.

The assembling the cartridge units at step 10 may include, for example:assembling and delivering open-ended, partially-assembled cartridgeunits; establishing a procession of the open-ended, partially-assembledcartridge units; adding liquid to the liquid supply region of thecartridge units; inserting a respective downstream gasket into each ofthe cartridge units; inserting a respective mouth-end insert into eachof the cartridge units; and applying a respective label to the outerhousing of each of the cartridge units.

The assembling battery sections at step 11 may include, for example:establishing a procession of partially-assembled battery sections;inserting at least one of a puff sensor, a battery, and controlcircuitry in each of the battery sections; and applying a respectivelabel to the outer housing of each of the battery sections. Steps 10 and11 may be performed in any desired order, including in series with oneanother, in parallel with one another, intermittently in series and/orparallel, etc.

The assembling the combined article at step 12 may include, for example:connecting a respective cartridge unit to a respective battery section.In this manner, the combined article is an electronic vapor device 60comprising a cartridge unit 70 connected to a battery section 72 such asthat shown in FIGS. 1a or 1 d.

In example embodiments, the processes performed at steps 10-12 areautomated, e.g., using computer-controlled manufacturing machinery. Inadditional aspects, the cartridge units 70 and battery sections 72 arehandled and transported during and between steps 10-12 in an automatedmanner, e.g., using rotating drums as described herein. In even furtheraspects, one or more inspection processes is performed during and/orafter each one of steps 10-12, e.g., to detect cartridge units 70 and/orbattery sections 72 that are out of specification. The method is notlimited to the particular steps 10-12; instead, more or less stepsand/or different steps and/or a different order of steps may be used.

FIGS. 2b-2d depict drum-to-drum transfer systems and methods that may beused with aspects of automated assembly of electronic vapor devices inaccordance with an example embodiment. Aspects shown in FIGS. 2b-2d maybe used in the handling and transporting of cartridge units 70 andbattery sections 72 during and between steps 10-12 described withrespect to FIG. 2a , for example. FIGS. 2b-2d are described with respectto sections 73 that are shown individually as solid circles and that mayrepresent cartridge units 70 or battery sections 72. As shown in FIG. 2b, a procession of a plurality of sections 73 may be carried by aplurality of rotating drums 20-24 to work stations 26, 27 wheremanufacturing/assembly processes are performed on the sections 73. Thework stations 26, 27 may correspond to any of steps 10-12. In addition,work station 26 may include machinery configured to insert a respectivedownstream gasket into each of the sections, and work station 27 mayinclude machinery configured to insert a respective mouth-end insertinto each of the sections. Although only two work stations 26, 27 areshown for simplicity, it is understood that rotating drums similar todrums 20-24 may be used to carry sections 73 to other work stationsduring the automated manufacture of electronic vapor devices.

In example embodiments, each drum 20-24 may include a cylindrical bodywith a plurality of grooves (also called flutes) spaced apart on itsroll face. Each flute may be structured and arranged to hold and carry asection 73 of an electronic vapor device, such as a cartridge unit orbattery section. As described in greater detail with respect to FIGS. 2cand 2d , each flute may include a resilient (e.g., yieldable) materialthat directly contacts the section 73 when the section 73 is held in theflute and carried by the rotating drum.

Still referring to FIG. 2b , each drum 20-24 may include a rotatablefluted drum portion and a fixed internal vacuum plenum. The vacuumsystem selectively applies a vacuum to vacuum ports in the flutes of therotatable drum portion as the latter rotates over the angular extent ofthe respective vacuum plenum. The communicated vacuum assists in holdingthe sections 73 in the flutes during rotation of the drum. For example,the system may be adapted such that during rotation of the drums 20-24,flutes that are located in shaded areas 30 are communicated with avacuum, while flutes that are located in unshaded areas 31 are notcommunicated with a vacuum. Specifically, a particular flute oncounterclockwise rotating drum 20 is communicated with a vacuum when theflute is moving through the shaded area 30, and is not communicated witha vacuum when the flute is moving through the unshaded area 31. Vacuumis communicated to each flute on each drum individually, such as via avacuum port in each flute and a vacuum source internal to the drum thatselectively applies a vacuum force to the vacuum port in a particularflute based on the angular position of the particular flute along therotational path of the roll face of the drum.

Rails 32 may also be provided adjacent to one or more of the drums 20-24to assist in maintaining the sections 73 in the flutes. Further,cleaning air may be communicated to the port(s) of each flute at angularpositions such as that indicated by area 33. The cleaning air may beselectively applied to each flute individually.

In example embodiments, when transferring a section 73 from a donatingflute of a first drum to a receiving flute of a second drum, e.g., fromdrum 20 to drum 21, a vacuum force is deactivated at the donating flutewhen the donating flute is at a location prior to the nip 35 between thefirst drum and the second drum. Also, a vacuum force is activated at thereceiving flute when the receiving flute is at a location prior to thenip 35 between the first drum and the second drum. This coordination ofthe timing of the respective vacuum forces applied at the donating fluteand the receiving flute is depicted by shaded areas 30 and unshadedareas 31 in FIG. 2b and facilitates moving the section 73 out of thedonating flute and into the receiving flute.

With continued reference to FIG. 2b , the system may include acontroller “C” that is operatively connected to one or more elements. Asdescribed herein, the controller “C” may be a computer-based controllerthat employs hardware and software to perform automated controlprocesses. For example, the controller “C” may be operatively connectedto one or more detectors 40 for the purpose of inspecting and/ortracking sections 73 during the automated manufacturing. The detectors40 may comprise cameras or other optical detecting mechanisms thatdetect optical characteristics and/or information of the sections 73 andtransmit the detected optical characteristics and/or information to thecontroller “C”.

For inspection purposes, the controller “C” may determine whether asection 73 is out of specification, e.g., not properly assembled,damaged, etc., by comparing the detected optical characteristics topredefined optical criteria. Any section 73 that is determined to be outof specification based on the detecting may be ejected from one of therotating drums, e.g., by selectively applying a jet of air to the flute,e.g., as indicated at location 41, to eject the section 73 from theflute. It is envisioned that an inspection station may be locateddownstream of the ejection station 41, to confirm proper operation ofthe ejection station 41. The controller “C” may be programmed to trackany empty flute position resulting from an ejection, and to track theempty flute position through the system (e.g., the entire system or tothe next downstream workstation).

Alternatively or in addition, for tracking purposes, each section 73 maybe encoded with information such as: date of manufacture, uniquetracking identification, authentication, lot number, facilityidentification, and model number. More specifically, the individualsections 73 may be printed with indicia that provide such information.The detectors 40 may include a device, such as a camera or bar codereader, which reads the encoded information on each of the cartridgeunits as the sections are moved by the drums 20-24. The controller “C”may be programmed to track the position of each section 73 in the systembased on the encoded information detected by the detectors 40.

As depicted in FIG. 2b , the controller “C” may also be operativelyconnected to the drums 20-24, for example, to control the rotationalspeed of each drum. The controller “C” may also be operatively connectedto the work stations 26, 27, for example, to control aspects of theautomated processes that are performed at the stations.

FIGS. 2c and 2d show aspects of the flutes and drums as describedherein. In example embodiments, the flutes 50 that receive and carry thesections 73 are embodied as grooves or channels at the outer surface(e.g., roll face) of the rotating drums (e.g., drums 20-24). As shown inFIG. 2c , the longitudinal axis of the section 73 is transverse to thedirection of rotation of the drum when the section 73 is seated in theflute 50. Each flute 50 may include at least one port 52 that is incommunication with a vacuum/pressure source of the drum. Depending onthe angular location of the flute 50 along the rotational path of thedrum, the vacuum/pressure source of the drum may selectively apply avacuum, an air jet, or no force at the port 52, e.g., as described withrespect to areas 30, 31, and 33 of FIG. 2 b.

As shown in the magnified portion 53 of FIG. 2c , in non-limitingembodiments there is a clearance 54 between the roll surfaces of therespective drums (e.g., drums 20 and 21) at the nip 35 between thedrums. For example, when the section 73 has an outside diameter of about7.8 mm, the clearance 54 may be about 0.5 mm to about 1 mm, although anysuitable dimension of clearance may be used.

As shown in FIG. 2d , the surface of each flute 50 may be coated orcovered with a resilient (e.g., yieldable) material 55. An opening 56 inthe resilient material 55 aligns with the port 52 such that vacuum or anair jet may be applied to the flute via the port 52 and opening 56. Theresilient material 55 may be applied to surfaces of the drum outside ofthe flutes 50, for example, over the entire roll face of the drum. Inanother embodiment, the entire drum (e.g., drums 20-24) may beconstructed of the resilient material 55. In another embodiment, theresilient material 55 is provided over less than the entire flute 50;for example, a seat of resilient material may be provided in asub-section of a flute. Such a resilient material 55 may be used withany type of drum based on the system requirements, including but notlimited to a wrapping drum, MR drum, roll hand, etc.

In accordance with aspects herein, the resilient material 55 comprises amaterial that is softer (i.e., has a lower hardness) than the materialof the outer surface of the section 73. For example, in a non-limitingembodiment, the outer surface of a section 73 may be composed of a metalor metal alloy and the resilient material 55 may be composed of aplastic or rubber material. The outer surface may be composed of analuminum alloy and the resilient material 55 is composed ofpolyoxymethylene (POM, Delrin, etc.), although example embodiments arenot limited to these materials and any suitable materials may be used.

The resilient material 55 facilitates handling the sections 73 duringthe speeds that are involved with the rotating drums during theautomated manufacture of electronic vapor devices 60 as describedherein. In particular, the yieldable nature of the resilient material 55promotes a more complete seal of the section 73 at the vacuum port in aflute, which enhances the vacuum retention force applied to the section73 in the flute. Such arrangement assures retention of articles on theflutes even at higher production speeds and/or with heavier, largerarticles.

FIG. 3 shows aspects of a system 200 for the automated assembly ofelectronic vapor devices in accordance with an example embodiment. Inexample embodiments, the system 200 includes a labeler workstation 201that operates to automatically apply a label (e.g., wrapper) on an outersurface of each battery section 72. The labeler workstation 201 mayoperate in a manner disclosed in U.S. Patent Application No. 61/979,330and/or U.S. Pat. No. 5,024,242, the entire contents of both of which areexpressly incorporated herein by reference. The system 200 also includesan assembler workstation 300 that operates to automatically connect arespective cartridge unit 70 to a respective battery section 72 tocomplete a fully assembled electronic vapor device, such as that shownin FIGS. 1a and 1 d. The labeler workstation 201 and the assemblerworkstation 300 each may include rotating drums that transport cartridgeunits 70 and/or battery sections 72 using drum-to-drum transporttechniques as described with respect to FIGS. 2b -2 d.

With reference to FIG. 3, in example embodiments the labeler workstation201 may include an accumulator 202 that receives and holds a pluralityof battery sections 72 after each battery section 72 has been assembledwith a puff sensor, battery, and control circuitry, for example asdescribed with respect to step 11 of FIG. 2a . The accumulator 202 maycomprise, for example, a zig-zag or S-shaped pathway through which thebattery sections 72 travel between an accumulator inlet and anaccumulator outlet 203. The accumulator inlet may be vertically higherthan the accumulator outlet 203 such that the battery sections 72 travelthrough the accumulator via gravity. The accumulator 202 may be sized toreceive battery sections 72 at the accumulator inlet at a faster ratethan battery sections 72 are released at the accumulator outlet 203. Inthis manner, the accumulator 202 provides a buffer that compensates forempty slots in the procession, e.g., battery sections 72 that wereejected from the procession based on the inspection step or missing inthe procession as a result of inconsistent loading.

A sensor 204, such as a photo eye or similar, may be arranged at theaccumulator 202 to determine whether the amount of battery sections 72in the accumulator 202 exceeds a threshold. The sensor 204 may beoperatively connected to a controller of the system 200. When the sensor204 communicates to the controller that the level of battery sections 72in the accumulator 202 falls below the threshold, the controller maytemporarily stop the drums downstream of the accumulator 202, i.e., topause the labeling operation. This pausing permits battery sections 72to accumulate in the accumulator 202 since the upstream equipment maycontinue to process and deliver battery sections 72 to the accumulator202. The sensor 204 detects when a sufficient number of battery sections72 has accumulate in the accumulator 202 (i.e., exceeds the threshold),at which time the controller, based on the signal from the sensor 204,automatically re-starts the drums of system 200 to resume the labelingoperation.

In example embodiments, a transfer drum 206 with flutes 50 around itsouter perimeter receives battery sections 72 from the accumulator outlet203. The transfer drum 206 may be similar to the drums 20-24 describedwith respect to FIG. 2b . For example, each flute 50 of the transferdrum 206 is sized to receive a single battery section 72. Each flute mayalso be provided with a resilient material 55 for contacting the batterysection 72. Each flute 50 may also have at least one aperture (such asport 52 and opening 56) that is configured to selectively communicate avacuum force to a cartridge unit seated in the flute 50, i.e., forkeeping the battery section 72 seated in the flute 50.

In example embodiments, the system is arranged such that rotation of thedrum 206 in a first rotational direction moves an empty flute 50 pastand under the accumulator outlet 203. Gravity pulls a battery section 72at the accumulator outlet 203 into the empty flute 50. In addition to oralternatively to gravity, air pressure and/or a positive force appliedby a wheel or belt may be used to move the battery section 72 at theaccumulator outlet 203 into the empty flute 50. Vacuum may also beselectively applied to the flute 50 to assist in pulling the batterysection 72 from the accumulator outlet 203 into the empty flute 50. Asthe drum 206 continues to rotate, the trailing wall of the flute 50strips the battery section 72 from the accumulator outlet 203. Vacuummay be selectively applied to the flute 50 to maintain the batterysection 72 in the flute 50 until rotation of the drum 206 brings thecartridge unit to the next rotating drum 211.

At location 210, the battery sections 72 are transferred from thetransfer drum 206 to a drum 211, which rotates in a second rotationaldirection opposite the first rotational direction of the drum 206. Eachbattery section 72 is held in a respective seat on the drum 211. Atagging system 215 is situated adjacent drum 211 and may include atagging drum that rotates in the first rotational direction. In exampleembodiments, the tagging drum carries a plurality of labels and applies(i.e., tags) a respective label to a respective battery section 72 atlocation 225. The tagging system 215 may be structured and arranged tocut each individual label from a continuous web 216 that has a pressuresensitive adhesive on one side. The web 216 may be wound on a spool 217.

At location 230, each battery section 72 with its associated label istransferred from the drum 211 to a rolling drum 235, which rotates inthe first rotational direction. Rolling drum 235 conveys each batterysection 72 and its associated label into contact with belt 240. The belt240 moves in a same direction as an adjacent portion of the surface ofthe rolling drum 235 but at a slightly slower speed than the rotation ofthe rolling drum 235, the speed difference between the belt 240 and therolling drum 235 causing the battery section 72 to rotate in a directionthat causes label to wrap itself around the exterior surface of thebattery section 72. After the wrapping operation, the labeled batterysections 72 are transferred from the rolling drum 235 to a downstreaminspection drum 245.

Still referring to FIG. 3, the labeler workstation 201 may include adetector 250 adjacent the inspection drum 245. The detector 250 may besimilar to detector 40 described with respect to FIG. 2b and operates aspart of an inspection system for inspecting each battery section 72 onthe inspection drum 245. For example, the detector 250 may comprise oneor more cameras or other optical detecting mechanisms that detectoptical characteristics and/or information of the battery section 72 andtransmit the detected optical characteristics and/or information to thecontroller “C”. For inspection purposes, the controller “C” maydetermine whether a battery section 72 is out of specification, e.g.,not properly labeled, damaged, etc., by comparing the detected opticalcharacteristics to predefined optical criteria.

After the inspection at the inspection drum 245, the battery sections 72may be transferred from the inspection drum 245 to a rejection drum 255.Any battery section 72 that is determined to be out of specificationbased on the inspection performed at the inspection drum 245 may beejected from the rejection drum 255, e.g., by selectively applying a jetof air to the flute as indicated at location 260 to eject the batterysection 72 from a flute of the rejection drum 255 into a reject chute orbin 265.

With continued reference to FIG. 3, the battery sections 72 aretransferred from the rejection drum 255 to the assembler workstation300. One or more rotating transfer drums 265 a, 265 b, . . . , 265 nconvey the battery sections 72 from the rejection drum 255 to theassembler workstation 300 using rotating drum transport principles asdescribed with respect to FIGS. 2b -2 d.

In example embodiments, the assembler workstation 300 includes a feeddrum 305 with flutes around its outer perimeter that receives cartridgeunits 70 and battery sections 72. The feed drum 305 is a rotating drumsimilar to drums 20-24 of FIGS. 2b-2d in which each flute is sized tosimultaneously hold a cartridge unit 70 and a battery section 72 in aspaced apart and axially aligned orientation. The feed drum 305 mayreceive the cartridge units 70 from an accumulator 310 in a mannersimilar to that described with respect to drum 206 and accumulator 202.The accumulator 310 may receive the cartridge units 70 from a conveyor315 and may operate as a buffer between the conveyor 315 and the feeddrum 305. The conveyor 315 may comprise a fluted drum and/or fluted beltthat conveys a procession of assembled cartridge units 70 to theassembler workstation 300 from another part of an assembly line. Forexample, the conveyor 315 may receive the cartridge units 70 after eachcartridge unit 70 has been assembled in the manner described withrespect to step 10 of FIG. 2 a.

Specifically, as shown in FIG. 3, the feed drum 305 receives a cartridgeunit 70 in an empty flute on the perimeter of the feed drum 305 as theflute moves past the outlet of the accumulator 310 due to the rotationof the feed drum 305. After passing the accumulator 310, the flute holdsonly a cartridge unit 70 therein. The rotation of the feed drum 305causes the flute holding the cartridge unit 70 to move from the outletof the accumulator 310 toward a nip 316 between the feed drum 305 andthe transfer drum 265 n where a battery section 72 is transferred fromthe transfer drum 265 n into the flute of the feed drum 305 usingdrum-to-drum transfer as described herein. After passing the nip 316,the flute holds the cartridge unit 70 (received from the accumulator310) and the battery section 72 (received from the drum 265 n). Inexample embodiments, the accumulator 310 and the transfer drum 265 n arelocated relative to the feed drum 305 such that the cartridge unit 70 isreceived in a first section of the flute and the battery section 72 isreceived in a second section of the flute. In this manner, the cartridgeunit 70 and the battery section 72 are held in the flute in a spatialorientation in which they are aligned with one another along theirrespective longitudinal axes, and are spaced apart from one anotheralong this longitudinal direction. Vacuum may be used to hold thecartridge unit 70 and the battery section 72 in the flute in the mannerdescribed herein.

The rotation of the feed drum 305 causes the flute holding the cartridgeunit 70 and the battery section 72 to move toward a nip 320 between thefeed drum 305 and a transfer drum 325. At the nip 320, the cartridgeunit 70 and the battery section 72 are both transferred from the fluteof the feed drum 305 to a flute of the transfer drum 325 usingdrum-to-drum transfer as described herein. After passing the nip 320,the flute of the feed drum 305 is empty and moves toward to theaccumulator 310 to receive another cartridge unit 70 and repeat theprocess.

Still referring to FIG. 3, in an example embodiment the cartridge unit70 and the battery section 72 are transferred from the transfer drum 325to an assembly drum 330 by way of at least one intermediate transferdrum 326. The cartridge unit 70 and the battery section 72 are held onthe respective drums and moved from one drum to another using vacuumretention and drum-to-drum transfer as described herein. Any desirednumber of transfer drums 325 and 326 may be used between the feed drum305 and the assembly drum 330. Alternatively, the transfer drums 325 and326 may be omitted and the cartridge unit 70 and the battery section 72may be moved directly from the feed drum 305 to the assembly drum 330.

In accordance with aspects described herein, the cartridge unit 70 andthe battery section 72 that are held in a flute of the assembly drum 330are connected to one another to form a completed electronic vapordevice. In example embodiments, the connecting is performed bytranslating the cartridge unit 70 toward the battery section 72 in theflute (or vice versa), and rotating the cartridge unit 70 or batterysection 72 or both relative to each other in the flute such that aphysical engagement is established between the cartridge unit 70 and thebattery section 72. A swash plate (shown in FIG. 6) may cause thetranslational movement by pushing the cartridge unit 70 toward thebattery section 72 within the flute, and belts 335, 336 may cause therotational movement by engaging respective surfaces of the cartridgeunit 70 and the battery section 72 in the flute. The connected cartridgeunit 70 and battery section 72 constitute a completed electronic vapordevice 60 that is transferred from the assembly drum 330 to a nextdownstream drum 340 using drum to drum transfer as described herein.

Still referring to FIG. 3, the assembler workstation 300 may include anumber of fluted drums 340-343 downstream of the assembly drum 330. Inexample embodiments, the drums 340-343 operate using rotating drumtransport principles including vacuum retention and drum-to-drumtransfer as described with respect to FIGS. 2b -2 d. One or moredetectors are provided for inspecting the assembled electronic vapordevices 60 downstream of the assembly drum 330. For example, a firstdetector 345 and a second detector 346 may be arranged adjacentinspection drums 340 and 341 downstream of the assembly drum 330. Thedetectors 345, 346 may comprise cameras or other optical detectingmechanisms that detect optical characteristics of the electronic vapordevices 60 and transmit the detected optical characteristics to acontroller “C”. In turn, the controller “C” may determine whether anelectronic vapor device 60 is out of specification, e.g., damage to thelabel on the cartridge unit 70, damage to the label on the batterysection 72, amount of gap between the cartridge unit 70, damage to thelabel on the battery section 72, overall length of the assembledelectronic vapor device 60 etc., by comparing the detected opticalcharacteristics to predefined optical criteria. Any electronic vapordevice 60 that is determined to be out of specification based on thedetecting may be ejected from one of the rotating drums, e.g., byapplication of a jet of air at 350 to eject the electronic vapor device60 from a flute of the drum 342 and into a reject chute or bin 355.

FIG. 4 shows a flute 405 of the assembly drum 330 in accordance withaspects herein. The flute 405 may be similar to flute 50 shown in FIGS.2c and 2d in that the flute 405 is at the outer roll face 410 of theassembly drum 300 and a longitudinal axis 411 of the flute 405 isperpendicular to the direction of rotation of the assembly drum 330. Inexample embodiments, the flute 405 includes vacuum ports 420 forcommunicating a vacuum to a cartridge unit 70 and a battery section 72positioned in the flute 405. The flute 405 may also include at least oneair bearing port 425 for providing an air bearing between the surface ofthe flute 405 and at least one of the cartridge unit 70 and the batterysection 72, as described in greater detail herein.

Still referring to FIG. 4, the assembly drum 330 may also include firstrollers 435 extending outward from the roll face 410 on opposite sidesof the flute 405. The assembly drum may also include second rollers 436extending outward from the roll face 410 on opposite sides of the flute405. The rollers 435 and 436 are configured to engage the belts 335 and336, respectively, as described in greater detail with respect to FIGS.7 and 8. In example embodiments, the roll face 410 of the assembly drum330 includes a plurality of flutes 405 and associated sets of rollers435, 436.

FIGS. 5a-5c show aspects of connecting a cartridge unit 70 and a batterysection 72 in a flute 405 of the assembly drum 330. FIG. 5a shows thecartridge unit 70 and the battery section 72 in a flute 405 at a firstrotational position of the assembly drum 330. FIG. 5b shows thecartridge unit 70 and the battery section 72 in a flute 405 at a secondrotational position of the assembly drum 330 after the first rotationalposition. FIG. 5c shows the cartridge unit 70 and the battery section 72in a flute 405 at a third rotational position of the assembly drum 330after the second rotational position.

As shown in FIG. 5a , the cartridge unit 70 and the battery section 72are initially held in the flute 405 in an axially aligned and spacedapart relation relative to one another. Specifically, a longitudinalaxis 505 of the cartridge unit 70 is substantially aligned (coaxial)with a longitudinal axis 506 of the battery section 72 and parallel tothe axis 411 of the flute 405. Moreover, there is a clearance 507between the connection structure 501 of the cartridge unit 70 and theconnection structure 502 of the battery section 72. In exampleembodiments, an end of the battery section 72 opposite the connectionstructure 502 is held against a limit stop 510, which may be anysuitable structure that is affixed to or part of the assembly drum 330that prevents movement of the battery section 72 in the directionindicated by arrow 511.

As shown in FIG. 5b , the cartridge unit 70 is translated in the flute405 toward the battery section 72. The translation may be caused, forexample, by a swash plate 525 connected to the assembly drum 330 asshown in FIG. 6. In an example embodiment, the swash plate 525 rotateswith the assembly drum and is pushed inward toward the flute 405 by apusher 530 as shown in FIG. 6. The pusher 530 may comprise, for example,a roller or cam that is fixedly mounted to remain stationary while theassembly drum 330 rotates. As the swash plate 525 and the assembly drum330 rotate past the pusher 530, the pusher 530 contacts a portion of theswash plate 525 and pushes (moves) that portion of the swash plate 525toward the assembly drum 330, and this inward movement causes the swashplate 525 to contact the cartridge unit 70 and push the cartridge unit70 toward the battery section 72 in the flute 405 as shown in FIG. 5 b.

In an example embodiment, the first connection structure 501 is a malethreaded structure and the second connection structure 502 is a femalethreaded structure that corresponds to the male threaded structure insize and shape. In this embodiment, the length of the flute 405 asdefined by the limit stop 510 is configured such that the translationalmovement of the cartridge unit 70 by the swash plate 525 causes thefirst connection structure 501 to be positioned sufficiently closerelative to the second connection structure 502 such that subsequentrotation of the cartridge unit 70 or battery section 72 or both willcause the male threaded structure to threadingly engage female threadedstructure.

As shown in FIG. 5c , the cartridge unit 70 or the battery section 72 orboth are rotated in the flute 405 to complete the connection of thefirst connection structure 501 and the second connection structure 502,resulting in the cartridge unit 70 and battery section 72 being combinedas a completed electronic vapor device 60. In example embodiments, therotation depicted in FIG. 5c is achieved using at least one of the belts335 and 336. The elements of the assembler workstation may be structuredand arranged such that the belt 335 causes the cartridge unit 70 torotate about its axis 505 within the flute 405, and such that belt 336causes battery section 72 to remain stationary within the flute 405while the cartridge unit 70 is rotating (or vice versa), thereby causingrelative rotation between the cartridge unit 70 and the battery section72 that operates to thread the first connection structure 501 into tothe second connection structure 502.

With continued reference to FIGS. 5b and 5c , the translation and therotation may occur in successive steps or may occur simultaneously. Inan example embodiment, the belt 335 engages the cartridge unit 70 andbegins to rotate the cartridge unit 70 while the swash plate 525 istranslating the cartridge unit 70 in the flute 405. In this manner, thecartridge unit 70 is rotating as it translates toward the batterysection 72. In this embodiment, the belt 335 continues to rotate thecartridge unit 70 after a termination of the translational movementcaused by the swash plate 525, and this continued rotation operates tothread the first connection structure 501 into to the second connectionstructure 502.

FIGS. 6 and 7 show aspects of the assembly drum 330 and the belts 335and 336 in accordance with aspects herein. In example embodiments, theassembly drum 330 includes plural flutes 405, rollers 435 aligned withbelt 335, and rollers 436 aligned with belt 336. The swash plate 525 isconnected to the assembly drum 330 and the pusher 530 mounted in a fixedrelationship relative to the swash plate 525 and the assembly drum 330(the swash plate 525 is omitted from view in FIG. 7 to illustrate otherelements). In the implementation depicted in FIGS. 6 and 7, the belts335 and 336 are both driven by a same actuator 605 by way of a firstdrive wheel 615 and a second drive wheel 616 connected to a rotatingshaft 620 extending from the actuator 605. Alternatively, the belts 335and 336 may be driven independent of one another using separateactuators.

According to aspects herein, the first belt 335 is driven at a firstspeed relative to the assembly drum 330 and the second belt 336 isdriven at a second speed relative to the assembly drum 330 differentthan the first speed. By driving the belts 335 and 336 at differentspeeds, the rotational motion of the cartridge unit 70 relative to thebattery section 72 described with respect to FIG. 5c is obtained. In anexample embodiment, the second belt 336 is driven at a second speedsubstantially equal to the rotational speed of the roll face 410 of theassembly drum 330. In this manner, when the second belt 336 engages thebattery section 72 in the flute 405, the speed of the second belt 336matches the speed at which the battery section 72 is being moved by theassembly drum 330 such that the second belt 336 holds the batterysection 72 in the flute 405 without rotating the battery section 72relative to the flute 405. Also, the first belt 335 may be driven at afirst speed that is different than the rotational speed of the assemblydrum 330. In this manner, when the first belt 336 engages the cartridgeunit 70 in the flute 405, the difference in speed between the first belt335 and the assembly drum 330 causes the cartridge unit 70 to rotatewithin the flute 405. The first speed of the first belt 335 may befaster or slower than the rotational speed of the assembly drum 330depending on the desired rotational direction of the cartridge unit 70within the flute 405 and relative to the battery section 72.Specifically, the first speed of the first belt 335 may be selected tocause the cartridge unit 70 to rotate in a direction relative to thebattery section 72 that causes the male threaded structure of the firstconnection structure 501 to engage and drive into the female threadedstructure of the second connection structure 502.

With continued reference to FIGS. 6 and 7, in example embodiments thefirst drive wheel 615 and the second drive wheel 616 have differentrespective diameters, which operate to drive the belts 335 and 336 atdifferent respective speeds as described herein. As particularly shownin FIG. 7, the first belt 335 may be driven as an endless loop aroundthe first drive wheel 615 and two other wheels 641 and 651, and thesecond belt 336 may be driven as an endless loop around the second drivewheel 616 and two other wheels 642 and 652. The wheels 615, 641, and 651may each have a smaller diameter than the wheels 616, 642, and 652. Thisarrangement of wheels is not limiting, however, and any suitable systemmay be used for driving the first belt 335 at a different speed than thesecond belt 336.

In example embodiments, the belts 335 and 336 are composed of a materialthat has a relatively high coefficient of friction such that the belts335 and 336 sufficiently engage cartridge unit 70 and the batterysection 72, respectively, when the belts come into contact with theseelements. For example, the belts 335 and 336 may be composed of (orcoated with) non-slick natural rubber. Conversely, the surface of theflute 405 may be coated with a material that has a relatively lowcoefficient of friction to permit the cartridge unit 70 and/or thebattery section 72 to move within the flute 405. An example of anacceptable coating material may be nickel-phosphor alloy, although anysuitable coating may be used.

FIG. 7 also shows areas where vacuum is selectively communicated to theflutes 405 of the assembly drum 330 in accordance with aspects herein.The assembly drum 330 may include a rotatable drum portion and a fixedinternal vacuum plenum that are structured and arranged to selectivelyapply a vacuum force to the vacuum ports 420 in a particular flute 405based on the angular position of the particular flute 405 along therotational path of the rotatable drum portion, e.g., in a manner similarto that described with respect to FIG. 2b . In example embodiments, thevacuum system of the assembly drum 330 is configured to communicatevacuum to the ports 420 of a particular flute 405 when the flute 405 ismoving through the regions 711 and 713, and to not communicate vacuum tothe ports 420 of the flute 405 when the flute 405 is moving through theregions 712.

Region 711 extends from a first location 721 where a flute 405 receivesa cartridge unit 70 and a battery section 72 from the upstream drum 326to a second location 722 where the belts 335 and 336 come into contactwith the cartridge unit 70 and the battery section 72 held in the flute405. Region 712 extends from the second location 722 to a third location723 where the belts 335 and 336 go out of contact with the cartridgeunit 70 and the battery section 72 held in the flute 405. Region 713extends from the third location 723 to a fourth location 724 where thecompleted electronic vapor device 60 is transferred from the flute 405to another flute of the downstream drum 340. In this manner, vacuum isinterrupted (not applied) to the flute 405 when the cartridge unit 70and/or the battery section 72 are undergoing the translational androtational movements as described with respect to FIGS. 5b and 5 c.

FIG. 8a shows a side view of the assembly drum 330 with an empty flute405. FIG. 8b shows a side view of the assembly drum 330 with a cartridgeunit 70 in the flute 405. In example embodiments, the rollers 435 extendradially outward beyond the roll face 410 of the assembly drum 330 by adimension “X”, and the cartridge unit 70 extends radially outward beyondthe roll face 410 by a dimension “Y”. The rollers 435 are configuredsuch that the magnitude of dimension X is sufficient to provide aclearance 805 between the belt 335 and the roll face 410 when the flute405 is empty, as shown in FIG. 8a . The rollers 435 are also configuredsuch that the magnitude of dimension X is less than the magnitude ofdimension Y, such that the belt 335 engages the outer surface of thecartridge unit 70 that is held in the flute 405, as shown in FIG. 8b .The rollers 435 may comprise, for example, bearings that are rotatablymounted in the assembly drum 330 and that are free to rotate about anaxis that is parallel to and offset from the axis 411 of the flute 405,for example as shown in FIG. 9. Alternatively, the rollers 435 maycomprise bushings that are fixed relative to the assembly drum 330 andcomposed of a material that provides low-friction contact with the belt335. The rollers 436 may be arranged in a manner similar to the rollers435 to provide a clearance between the belt 336 and the roll face 410while permitting the belt 336 to engage the battery section 72.

FIG. 9 shows a cutaway view of a portion of the assembly drum 330 inaccordance with aspects herein. Specifically, FIG. 9 shows a rotatabledrum portion 905 of the assembly drum 330 that rotates around a fixedinternal vacuum plenum (not shown). As described herein, the geometry ofthe rotatable drum portion 905 and the fixed internal vacuum plenum arestructured and arranged to selectively apply a vacuum force to thevacuum ports 420 in a particular flute 405 based on the angular positionof the particular flute 405 along the rotational path of the rotatabledrum portion 905, e.g., in the manner described with respect to FIGS. 2band 7.

FIG. 9 also shows an air system that operates to selectively supplycompressed air to the air bearing ports 425 of a flute 405 in accordancewith aspects herein. In example embodiments, the air system includes amanifold 910 adjacent the rotatable drum portion 905 of the assemblydrum 330. The manifold 910 remains stationary while the rotatable drumportion 905 rotates, and is structured and arranged to communicatecompressed air to the air bearing ports 425 of a particular flute 405 asthe flute 405 moves past a particular portion of the manifold 910.

The manifold 910 may include an inlet 915 that is connected to acompressed air source 920, such as shop air. The manifold 910 may alsoinclude an outlet port 925 that is fluidically connected to the inlet915 by one or more internal passages in the body of the manifold 910. Asshown in FIG. 10, the outlet port 925 has a limited extent thatcorresponds to a portion of the region 712 shown in FIG. 7.

With continued reference to FIG. 9, the rotatable drum portion 905 ofthe assembly drum 330 includes at least one port 930 associated witheach respective flute 405. The port 930 is fluidically connected to theair bearing ports 425 of its associated flute 405 by one or moreinternal passages in the rotatable drum portion 905. In exampleembodiments, the rotatable drum portion 905 and the manifold 910 aresized and shaped such that, during rotation of the rotatable drumportion 905, the port 930 moves past the outlet port 925 to temporarilyplace the port 930 in fluidic communication with the outlet port 925.While the port 930 is in communication with the outlet port 920,compressed air is communicated from the manifold 910 to the air bearingports 425 that are connected to the port 930. The compressed air flowsout of the air bearing ports 425 and exerts a force in a radiallyoutward direction on the cartridge unit 70 and the battery section 72that are in the flute 405. In this manner, the compressed air operatesto create an air bearing between the surface of the flute and thecartridge unit 70 and the battery section 72. The air bearing reducesthe friction between the surface of the flute and the cartridge unit 70and the battery section 72, which facilitates the translational androtational movement described with respect to FIGS. 5b and 5 c.

Still referring to FIG. 9, in example embodiments the manifold 910includes grooves 950 that receive protrusions 951 of the rotatable drumportion 905. The grooves 950 and protrusions 951 cooperate to formsealing rings around the outlet port 920 to inhibit compressed air fromescaping along a path between the surfaces of the manifold 910 and therotatable drum portion 905. The manifold 910 may be resiliently biasedtoward the rotatable drum portion 905, for example by one or moresprings 960, to maintain a sealing engagement between the grooves andprotrusions 951.

FIG. 11 shows a flow diagram 1100 that illustrates steps of a process inaccordance with aspects herein. At step 1101, a first section and asecond section of a product are arranged in a flute of a first rotatingdrum. The first and second sections may include, for example, sectionsof an electronic vapor-generating article, such as electronic vapingarticle. Specifically, the first and second sections may includesections of an electronic vapor device. More specifically, the firstsection may include a cartridge unit 70 and the second section mayinclude a battery section 72 as described herein. The rotating drum instep 1101 may be, for example, the feed drum 305 as described withrespect to FIG. 3. For example, step 1101 may include transferring acartridge unit 70 from an accumulator 310 to a flute of the feed drum305, and also transferring a battery section 72 from a drum 265 n to thesame flute of the feed drum 305, as described with respect to FIG. 3.

At step 1102, the first section and the second section are transferredfrom the flute of the first rotating drum to a flute of an assemblydrum. In example embodiments, the transferring includes drum-to-drumtransfer of the cartridge unit 70 and the battery section 72 directlyfrom the feed drum 305 to the assembly drum 330 or indirectly from thefeed drum 305 to the assembly drum 330 by way of one or moreintermediate transfer drums (e.g., drums 325, 326), as described in FIG.3 for example.

At step 1103, the first section is moved in a translational direction inthe flute of the assembly drum and relative to the second section. Inexample embodiments, the translational movement is caused by a firstmechanism that moves the first section relative to the second sectionwhile the first section and the second section are in the flute. In anon-limiting embodiment, the translational movement is caused by a firstmechanism comprising a swash plate or other suitable mechanism thatmoves the cartridge unit 70 toward the battery section 72 in the flutein a manner similar to the described with respect to FIG. 5 b.

At step 1104, the first section is moved in a rotational direction inthe flute of the assembly drum and relative to the second section. Inexample embodiments, the rotational movement is caused by a secondmechanism that rotates the first section relative to the second sectionwhile the first section and the second section are in the flute. In anon-limiting embodiment, the rotational movement is caused by a secondmechanism including a first belt 335 that engages the cartridge unit 70and rotates the cartridge unit 70 within the flute, and a second belt336 that engages the battery section 72 and holds the battery section 72stationary within the flute. In example embodiments, the rotationalmovement causes a first connection structure 501 of the cartridge unit70 to engage a second connection structure 502 of the battery section 72for coupling the cartridge unit 70 to the battery section 72 to form acomplete electronic vapor device 60. Step 1104 may be performedpartially or entirely concurrently with step 1103.

At step 1105, the connected first and second sections are transferredfrom the flute of the assembly drum to a flute of a downstream drum. Inexample embodiments, step 1105 includes transferring the completeelectronic vapor device 60 from the assembly drum 330 to drum 340 usingdrum-to-drum transfer, as described in FIG. 3 for example.

At step 1106, the connected first and second sections are inspected. Inexample embodiments, the inspection includes performing at least oneoptical inspection of the complete electronic vapor device 60 using atleast one detector 345, 346 and a controller “C” as described withrespect to FIG. 3. The inspection may include at least one of:inspecting a size of a gap between the connected first and secondsections; inspecting an overall length of the connected first and secondsections; and inspecting an appearance of one or more labels on theconnected first and second sections. Step 1106 may also include ejectingany connected first and second sections that fail the inspection asbeing out of specification.

In example embodiments, each of steps 1101-1106 are performed in anautomated manner, i.e., without a human operator touching the cartridgeunit 70 and/or the battery section 72 during any of the steps.

Although various non-limiting embodiments described herein translate androtate the first section 70, it is contemplated that instead of, or inaddition, the second section 72 may be translated and/or rotated.

The particulars shown herein are by way of example and for purposes ofillustrative discussion only and are presented in the cause of providingwhat is believed to be the most useful and readily understooddescription of the principles and conceptual aspects. In this regard, noattempt is made to show structural details in more detail than isnecessary for fundamental understanding, the description taken with thedrawings making apparent to those skilled in the art how the severalforms disclosed herein may be embodied in practice.

It is noted that the foregoing examples have been provided merely forthe purpose of explanation and are in no way to be construed aslimiting. While aspects have been described with reference to an exampleembodiment, it is understood that the words which have been used hereinare words of description and illustration, rather than words oflimitation. Changes may be made, within the purview of the appendedclaims, as presently stated and as amended, without departing from thescope and spirit of the present disclosure in its aspects. Althoughaspects have been described herein with reference to particular means,materials, and/or embodiments, the present disclosure is not intended tobe limited to the particulars disclosed herein; rather, it extends toall functionally equivalent structures, methods and uses, such as arewithin the scope of the appended claims.

1. An assembler system for assembling an electronic vaping article,comprising: an assembly drum configured to receive a first section and asecond section of the electronic vaping article; a first mechanismconfigured to push the first section along a surface of the assemblydrum and toward the second section; and a second mechanism configured torotate the first section on the surface of the assembly drum andrelative to the second section so as to connect the first section to thesecond section.
 2. The assembler system of claim 1, wherein one of thefirst section or the second section is a cartridge unit, and the otherof the first section or the second section is a battery section.
 3. Theassembler system of claim 1, wherein the first mechanism includes aswash plate configured to push the first section.
 4. The assemblersystem of claim 3, wherein the swash plate is configured to rotate withthe assembly drum.
 5. The assembler system of claim 3, wherein the firstmechanism includes a stationary pusher configured to move a portion ofthe swash plate to push the first section.
 6. The assembler system ofclaim 5, wherein the stationary pusher includes a roller or a cam. 7.The assembler system of claim 1, wherein the second mechanism includes afirst belt configured to engage the first section.
 8. The assemblersystem of claim 7, wherein the second mechanism includes a second beltconfigured to engage the second section.
 9. The assembler system ofclaim 8, wherein the first belt is configured to be driven at a firstspeed, and the second belt is configured to be driven at a differentsecond speed.
 10. The assembler system of claim 8, wherein the assemblydrum includes first rollers and second rollers, the first rollersextending outward from the assembly drum and configured to engage thefirst belt, the second rollers extending outward from the assembly drumand configured to engage the second belt.
 11. The assembler system ofclaim 1, wherein the first mechanism and the second mechanism areconfigured to push and rotate the first section simultaneously.
 12. Theassembler system of claim 1, wherein the assembly drum includes at leastone vacuum port and a vacuum system configured to selectivelycommunicate a vacuum to the first section and the second section throughthe at least one vacuum port.
 13. The assembler system of claim 12,wherein the vacuum system is configured to interrupt the vacuum when thefirst section is being pushed and rotated.
 14. The assembler system ofclaim 1, wherein the assembly drum includes at least one air bearingport and an air bearing system configured to selectively communicate apressurized gas to the at least one air bearing port.
 15. The assemblersystem of claim 14, wherein the air bearing system includes a manifold,the manifold including an inlet and an outlet port, the inlet being influidic communication with a source of the pressurized gas, the outletport configured to be temporarily in fluidic communication with a portof the assembly drum during a rotation of the assembly drum, the port ofthe assembly drum being in fluidic communication with the at least oneair bearing port.
 16. The assembler system of claim 1, furthercomprising: a feed drum arranged upstream from the assembly drum, thefeed drum configured to receive the first section at a first rotationalposition of the feed drum, the feed drum configured to receive thesecond section at a second rotational position of the feed drum.
 17. Theassembler system of claim 16, wherein the feed drum is configured totransfer the first section and the second section to the assembly drumat a third rotational position of the feed drum.
 18. The assemblersystem of claim 16, further comprising: a transfer drum arrangedupstream from the assembly drum and downstream from the feed drum, thefeed drum configured to transfer the first section and the secondsection to the transfer drum at a third rotational position of the feeddrum and prior to the first section and the second section beingreceived by the assembly drum.